Polaris RANGER 150 EFI 2020 Owner's Manual
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Polaris RANGER 150 EFI 2020 Owner's Manual

Polaris RANGER 150 EFI 2020 Owner's Manual

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2020
OWNER'S MANUAL
RANGER® 150 EFI

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Summary of Contents for Polaris RANGER 150 EFI 2020

  • Page 1 2020 OWNER’S MANUAL RANGER® 150 EFI...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 2020 Owner’s Manual RANGER 150 EFI...
  • Page 4 POLARIS®, RANGER®, POLARIS GENERAL®, and Ride Command® are trademarks of POLARIS Industries Inc. Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Specifications ....105 Polaris Products ....109 Troubleshooting .

  • Page 7: Messages

    POLARIS vehicle. Before your children drive or ride in the vehicle, please read and make sure they read this owner’s manual.
  • Page 8 You must learn how to keep yourself and those around you safe while you're riding. Your parents and POLARIS want you to be safe while you enjoy riding your new vehicle, and that's why it’s very important that you read this owner’s manual and watch the instructional video.

  • Page 9: Introduction

    INTRODUCTION INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
  • Page 10 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 11: Safety

    SAFETY SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. WARNING Modifying this vehicle in any way can change the top speed, stability and handling performance of this vehicle. Modifications that increase speed,...
  • Page 12 Over-the-ankle boots HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Always buckle and pull straps tight to ensure the helmet is secured.
  • Page 13 EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 14 SAFETY OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator and the supervising adult must understand how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand this owner’s manual and all warning and instruction labels before operating the vehicle.
  • Page 15 SAFETY PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).
  • Page 16 SAFETY CARRYING MULTIPLE PASSENGERS A passenger must always be seated in a passenger seat with seat belt secured. Carrying more than one passenger in this vehicle can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover.
  • Page 17 SAFETY TURNING IMPROPERLY Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 18 SAFETY Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed. CROSSING HILLSIDES Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover.
  • Page 19 SAFETY OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual.
  • Page 20 SAFETY OPERATING A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems.
  • Page 21 SAFETY • Do not over fill the tank. Do not fill the tank neck. • If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
  • Page 22 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. GENERAL WARNING WARNING The General Use Warning is located on the dashboard.
  • Page 23 • on hills steeper than 15˚. • on paved surfaces - pavement may seriously affect handling and control. • with non-Polaris approved accessories - they may seriously affect stability. • at speeds that are too fast for the operators skills, the conditions and/or the terrain.
  • Page 24 SAFETY BOX BAR WARNING The box bar warning is located on the box bar. WARNING NEVER tow, sit on, or hang from rack, bumper, or cargo bed. NEVER remove bumper. May result in severe injury or death. TIRE PRESSURE WARNING (7189047) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

  • Page 25: Features And Controls

    Promptly replace worn or damaged cab nets with new cab nets, available from your authorized POLARIS dealer. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets.
  • Page 26 FEATURES AND CONTROLS SEATS DRIVER’S SEAT ADJUSTMENT 1. Lift the seat latch lever located under the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever.
  • Page 27 10 ft. lbs. (13.5 Nm) SEAT BELTS This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for both the operator and passenger before riding. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 28 Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets or latches with new cab nets and latches. Your POLARIS dealer can assist. REAR BOX BAR This vehicle is equipped with a barrier...
  • Page 29 FEATURES AND CONTROLS FUEL CAP WARNING Never allow a child to refuel or handle gasoline. The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R +M/2 octane.
  • Page 30 • N: Neutral • R: Reverse Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving. This could damage the transmission.
  • Page 31 FEATURES AND CONTROLS PARKING BRAKE WARNING Operating the vehicle while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the vehicle.
  • Page 32 FEATURES AND CONTROLS BRAKE/THROTTLE PEDAL BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.

  • Page 33: Instrument Cluster

    This area displays engine RPM, ground speed, or coolant temperature. Display Area 1 A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled Service Indicator maintenance. See page 43 for more information.
  • Page 34 This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine Check Engine damage could result. Your authorized POLARIS dealer can assist. This lamp illuminates to indicate an overheated engine. If the Engine Hot indicator flashes, a severe overheating condition exists.
  • Page 35 INSTRUMENT CLUSTER DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Speed Engine Temperature Ambient Temperature (Optional)
  • Page 36 INSTRUMENT CLUSTER DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 Odometer Service Hours Trip 1 Trip Timer...
  • Page 37 INSTRUMENT CLUSTER Trip 2 Engine Temperature Voltage Ambient Temperature (Optional) GeoFence Status Engine Hours Speed...
  • Page 38 INSTRUMENT CLUSTER OPTIONS MENU Press and hold the MODE button to enter the Options Menu. OPTIONS MENU NOTES Diagnostic Codes Only displays if fault codes are present or stored Youth Menu Set passcode, maximum speed, and GeoFence settings. Units - Distance Select MPH or KPH Units - Temp Select between °F and °C...
  • Page 39 INSTRUMENT CLUSTER UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units-Distance” from the Options Menu by pressing the MODE button.
  • Page 40 INSTRUMENT CLUSTER UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 41 INSTRUMENT CLUSTER CLOCK 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 42 INSTRUMENT CLUSTER 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button. Toggle the Up/Down Buttons to change the units (12H or 24H) With the correct unit displayed, Press the mode button which will set the unit.
  • Page 43 INSTRUMENT CLUSTER BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.
  • Page 44 INSTRUMENT CLUSTER BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.
  • Page 45 INSTRUMENT CLUSTER SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 46 INSTRUMENT CLUSTER DIAGNOSTIC CODE NOTICE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item.
  • Page 47 INSTRUMENT CLUSTER YOUTH MENU 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 48 INSTRUMENT CLUSTER YOUTH MENU NOTES Maximum Speed Set maximum Speed GeoFence Enable/Disable GeoFence Inside GeoFence Speed Set inside Geofence maximum vehicle speed Outside GeoFence Speed Set outside GeoFence maximum vehicle speed Require PIN to start Enable/Disable PIN to start vehicle Start PIN delay Enable/Disable PIN delay Change PIN...
  • Page 49 3. Enter PIN. NOTICE If PIN is lost or displaced please contact your Polaris dealer for assistance. 4. To exit the Youth Menu the user can select Exit Menu function from Youth Menu, can hold MODE button and exit out of Youth Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
  • Page 50 INSTRUMENT CLUSTER MAX SPEED 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE Button. 3.
  • Page 51 NOTICE To use the geofence features, first download the Polaris Ride Command™ app and sign up. Turning the geofence on and off and changing the speeds can be done through the vehicle display once a geofence boundary has been created through the Ride Command app.
  • Page 52 INSTRUMENT CLUSTER Press the MODE button. Toggle the Up/Down buttons to cycle through options (On/Off). With the desired option displayed, press the MODE button which will set function and return to the Youth Menu. 5. To exit the Youth Menu the user can select Exit Menu function from Youth Menu, can hold Mode Button and exit out of Youth Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
  • Page 53 INSTRUMENT CLUSTER OUTSIDE GEOFENCE SPEED 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE button. 3.
  • Page 54 INSTRUMENT CLUSTER REQUIRE PIN TO START 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE button. 3.
  • Page 55 INSTRUMENT CLUSTER START PIN DELAY 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE button. 3.
  • Page 56 INSTRUMENT CLUSTER CHANGE PIN 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Youth Menu” by pressing the MODE button. 3.

  • Page 57: Operation

    Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
  • Page 58 OPERATION Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.
  • Page 59 OPERATION STARTING THE ENGINE 1. Position the vehicle on a level surface outdoors or in a well ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in NEUTRAL and apply the PARKING BRAKE. 4.
  • Page 60 OPERATION BRAKING 1. Release the throttle pedal completely. CAUTION When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking. 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.
  • Page 61 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: • Never exceed the stated load capacity for this vehicle. •...
  • Page 62 OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.
  • Page 63 OPERATION DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 2. Make sure all passengers are at least 10 years of age and tall enough to comfortably and safely sit in the passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3.
  • Page 64 OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 65 OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Avoid excessively steep hills. 2. Always travel straight uphill. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5.
  • Page 66 Give special attention to engine oil, transmission oil, and all grease fittings.If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your Polaris dealer can provide this service. If it’s impossible to bring the vehicle in before starting the engine, perform the services outlined on page 91, and take the vehicle in for service at the first opportunity.

  • Page 67: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.

  • Page 69: Maintenance

    PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 70 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized dealer or other qualified person perform these services. WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
  • Page 71 MAINTENANCE 50 HOUR / 500 MILE (800 KM) SERVICE ITEM REMARKS Inspect; cycle key to pressurize fuel pump; check lines and Fuel System fittings for leaks and abrasion Battery Check terminals; clean; test Inspect level; change yearly Main Gearcase Oil Engine Oil Change Valve lash adjustment: Every 40 hours after first 10-hour Valve Clearance...
  • Page 72 MAINTENANCE 100 HOUR / 1000 MILE (1600 KM) SERVICE ITEM REMARKS Battery Check terminals; clean; test Transmission (Main Gearcase) Replace transmission fluid Engine Oil Change Valve lash adjustment Valve Clearance Lubricate all fittings, pivots, cables, etc. General Lubrication Shift Linkage Inspect, lubricate, adjust Steering Lubricate...
  • Page 73 MAINTENANCE 150 HOUR / 1500 MILE (2400 KM) SERVICE ITEM REMARKS Inspect; cycle key to pressurize fuel pump; check lines and Fuel System fittings for leaks and abrasion Battery Check terminals; clean; test Inspect level; change yearly Main Gearcase Oil Engine Oil Change Valve lash adjustment Valve Clearance...
  • Page 74 MAINTENANCE ITEM REMARKS Spark Plug Inspect; replace as needed Engine Mounts Inspect Exhaust Muffler / Pipe Inspect Inspect for wear, routing, security; apply dielectric grease Wiring to connectors subjected to water, mud, etc. Clutches (Drive and Driven) Inspect; clean; replace worn parts Inspect;...
  • Page 75 POLARIS Chain Lube or See page 78 SAE 80/90 A-Arm Pivots POLARIS All Season Grease or grease conforming to NLGI No. 2 Grease at general lubrication interval, also after Steering Arm Pivots washing vehicle or driving in water. XU Perform these procedures more often for vehicles subjected to severe use.
  • Page 76 Maintenance Chart beginning on page 68. POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. See page 109 for the part numbers of POLARIS products.
  • Page 77 MAINTENANCE OIL CHANGE 1. Position the vehicle on a level surface. Set the parking brake. 2. Clean the area around the pre-filter plug. 3. Start the engine. Allow it to idle for two to three minutes. 4. Stop the engine. WARNING Hot oil can cause burns to skin.
  • Page 78 Follow Fluid Change Procedure to verify transmission is filled with fluid. Do not overfill. Always change the fluid at the intervals outlined in the Periodic Maintenance Interval Chart. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle. The fill plug is located on the side of the transmission gearcase.
  • Page 79 6. Add the recommended amount of lubricant through the fill plug hole . Do NOT overfill or fill to the bottom of the fill plug hole. FLUID CAPACITY Recommended Transmission Lubricant: Polaris AGL Capacity: 25 oz. (750 ml) 7. Reinstall the fill plug and torque to specification. TORQUE Transmission Fill / Drain Plug: 14 ft-lbs (19 N⋅m)
  • Page 80 DRIVE CHAIN LUBRICATION AND ADJUSTMENT Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such as in dirty or wet conditions.
  • Page 81 MAINTENANCE...
  • Page 82 MAINTENANCE PARKING BRAKE PARKING BRAKE CABLE FREEPLAY ADJUSTMENT 1. Inspect and perform any needed service on the brake pads before adjusting parking brake cable freeplay. 2. Make sure the parking brake is NOT set (the lever should be in the DOWN position).
  • Page 83 MAINTENANCE SPARK PLUG SPARK PLUG GAP/TORQUE Electrode Gap New Plug Torque Used Plug Torque 9-11 ft. lbs. 17-20 ft. lbs. 0.6-0.7 mm (12-15 Nm) (23-27 Nm) NOTICE Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 84 POLARIS dealer, or other qualified person, for service and repair assistance. • This CVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the CVT housing is securely in place during operation.
  • Page 85 MAINTENANCE 3. Allow the engine RPM to return to idle, then shift the transmission into gear. 4. Test the CVT system for belt slippage. If the belt slips, repeat the process or remove the outer clutch cover to inspect the CVT system. NOTE If the vehicle has ingested a large amount of water into the CVT system and has not been operated for a period of time, be sure to check the CVT system...
  • Page 86 MAINTENANCE 6. Place the air filter into the air box and reinstall the air box cover. NOTE Make sure the tabs are properly positioned into the hinge. Ensure the O-ring is installed inside the lid properly. 7. Engage the cover latches.
  • Page 87 MAINTENANCE SPARK ARRESTER WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Allow components to cool sufficiently before proceeding. •...
  • Page 88 MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding.
  • Page 89 Tighten any loose fittings and replace any worn or damaged parts. BRAKE FLUID Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 109 for the part numbers of POLARIS products. WARNING After opening a bottle of brake fluid, always discard any unused portion.
  • Page 90 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer or other qualified service facility before operating the vehicle.
  • Page 91 Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. The front and rear shock absorber springs are adjustable to increase or decrease spring tension.
  • Page 92 MAINTENANCE 4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line. 5. Again measure the distance between the marks and record. Call this measurement “3”. Subtract measurement “3” from measurement “2”. The difference between measurements “2”...
  • Page 93 8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 9. If water has been ingested into the transmission follow the procedure in the...
  • Page 94 Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
  • Page 95 MAINTENANCE WHEEL INSTALLATION WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.
  • Page 96 MAINTENANCE 6. If hub nut was removed, install a new cotter pin after the hub nut has been tightened. If the holes do not line up, turn the hub nut until the cotter pin can be installed. LIGHTS DAYTIME RUNNING LIGHT REPLACEMENT To remove the headlight, do the following: 1.
  • Page 97 MAINTENANCE BATTERY WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 98 MAINTENANCE BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the steps in the Battery Charging section before installing the battery. 1.
  • Page 99 MAINTENANCE NOTICE If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 1510 - 1.5 AMP charger (PN 2830404), which can be ordered through your dealer. During charging, place the charger outside of the vehicle and protect it from moisture. The battery charge port is located in the left rear wheel well, near the diagnostic plug.
  • Page 100 Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
  • Page 101 Replacement safety labels are provided by POLARIS at no charge. POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 102 MAINTENANCE CHROME WHEEL CARE (IF EQUIPPED) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
  • Page 103 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 104 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
  • Page 105 MAINTENANCE REMOVAL FROM STORAGE WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle.
  • Page 106 MAINTENANCE TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle. 1. Apply the brakes. 2. Place the transmission in PARK. Stop the engine. 3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 4.

  • Page 107: Specifications

    SPECIFICATIONS SPECIFICATIONS RANGER 150 EFI VEHICLE DIMENSIONS Length 85" (215.9 cm) 48" (121.9 cm) Width Height 58" (147.3 cm) 65” (165 cm) Wheel Base 8” (20.2 cm) Ground Clearance Minimum Turning Radius 90” (228.6 cm) Gross Vehicle Weight 1048 lbs (475 kg) Dry Weight 673 lbs (305 kg) Rear Rack/Box Capacity...
  • Page 108 SPECIFICATIONS ENGINE Engine Oil Requirement / 35.5 oz. / 1050 ml Capacity Exhaust System Single Headpipe / Single Silencer FUEL SYSTEM Throttle Body / Size Bosch / 32 mm Fuel Delivery Electronic Fuel Pump (in tank) 4 bar / 58 psi (400 kPa) Fuel Pressure Fuel Capacity 2.5 gal / 9.5...
  • Page 109 P3018 / 22 x 10-10 5 psi (34.4 kPa) Front Tire Air Pressure 5 psi (34.4 kPa) Rear Front Wheel Hydraulic Disc Brakes Rear Axle Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid CLUTCH SETTINGS SHIFT DRIVE DRIVEN ALTITUDE WEIGHT SPRING SPRING 0-3000 Meters No changes for high altitude.

  • Page 111: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS ENGINE LUBRICANT PART NUMBER DESCRIPTION 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 Synthetic 5W-50 4-Cycle Oil (qt./.95 2876245 PS-4 Synthetic 5W-50 4-Cycle Oil (gal./ 3.8 l) GEARCASE / TRANSMISSION LUBRICANTS PART NUMBER DESCRIPTION 2878068 AGL Full Synthetic Gearcase Lubricant &...
  • Page 112 POLARIS PRODUCTS PART NUMBER DESCRIPTION 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 113: Troubleshooting

    Inspect clutch seals for damage if repeated leaking system occurs. Clutch malfunction Your POLARIS dealer can assist. Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines. Your POLARIS dealer can assist.
  • Page 114 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Water or fuel in crankcase Your POLARIS dealer can assist. Clogged Fuel Filter Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC. Mechanical failure Your POLARIS dealer can assist. ENGINE BACKFIRES...
  • Page 115 Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter Your POLARIS dealer can assist malfunction Electronic throttle control Your POLARIS dealer can assist malfunction Other mechanical failure Your POLARIS dealer can assist...
  • Page 116 Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug Your POLARIS dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range...
  • Page 117 TROUBLESHOOTING DIAGNOSTIC TROUBLE CODES COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P1228 Voltage Above Normal, Or Shorted To High Source Accelerator Position 2 P1227 Voltage Below Normal, Or Shorted To Low Source P0123 Voltage Above Normal, Or Shorted To High Source Throttle Position Sensor...
  • Page 118 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P0112 Voltage Below Normal, Or Shorted To Low Source P2229 Voltage Above Normal, Or Shorted To High Source Barometric Pressure Sensor P2228 Voltage Below Normal, Or Shorted To Low Source P1217 Data Valid But Above Normal...
  • Page 119 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P0914 Data Erratic, Intermittent Or Incorrect Gear Sensor P0916 Voltage Below Normal, Or Shorted Signal To Low Source P1914 Abnormal Update Rate P153D Condition Exists Cruise Control Panel Switches P0335 Data Erratic, Intermittent Or Incorrect...
  • Page 120 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE P1691 Current Below Normal Or Open Circuit P0647 Voltage Above Normal, Or Shorted To High Source AC Compressor P0646 Voltage Below Normal, Or Shorted Clutch Relay To Low Source P0645 Current Below Normal Or Open...
  • Page 121 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 1347 P0232 Voltage Above Normal, Or Shorted To High Source 1347 Fuel Pump P0231 Voltage Below Normal, Or Shorted Driver Circuit To Low Source 1347 P0230 Current Below Normal Or Open Circuit 1557...
  • Page 122 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 3597 P16A1 Voltage Below Normal, Or Shorted To Low Source 3598 P16A9 Voltage Above Normal, Or Shorted To High Source ECU Output Supply Voltage 3598 P16A8 Voltage Below Normal, Or Shorted To Low Source 3599...
  • Page 123 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520200 P1502 Voltage Below Normal, Or Shorted To Low Source 520200 P1504 Special Instructions 520202 Voltage Above Normal, Or Shorted To High Source Canister Purge 520202 P0445 Voltage Below Normal, Or Shorted Valve...
  • Page 124 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520207 P1834 Voltage Below Normal, Or Shorted To Low Source 520207 P1836 Current Below Normal Or Open Circuit 520208 P1614 Voltage Above Normal, Or Shorted To High Source 520208 P1613 Voltage Below Normal, Or Shorted...
  • Page 125 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520268 P1515 Current Below Normal Or Open Circuit 520269 P1529 Voltage Above Normal, Or Shorted To High Source Idle Air Control 520269 P1528 Voltage Below Normal, Or Shorted M17 Stepper To Low Source Pin 4...
  • Page 126 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520279 P151D Condition Exists Throttle Body Control - Adaption Aborted 520280 P151E Condition Exists Throttle Body Control - Limp Home Position Check Failed 520281 P152A Condition Exists Throttle Body Control - Mechanical...
  • Page 127 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520305 P1530 Condition Exists Throttle Body Control - Requested Throttle Angle Not Plausible 520306 P1531 Condition Exists ECU ADC Fault - No Load 520307 P1532 Condition Exists ECU ADC Fault - Voltage 520308...
  • Page 128 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520333 P1139 Bad Intelligent Device Or Component 520336 P1545 Condition Exists ECU Monitoring (Pedal Map Mismatch) 520338 P2279 Condition Exists Gross Air Leak 520341 P0243 Voltage Above Normal, Or Shorted To High Source Wastegate 520341...
  • Page 129 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 520467 P071A Condition Exists Momentary Driveline Left Press 520468 P071D Condition Exists Momentary Driveline Right Press 520496 P107D Voltage Above Normal, Or Shorted To High Source Intercooler 520496 P107C...
  • Page 130 TROUBLESHOOTING COMPONENT P-CODE CONDITION DISPLAYED ON DISPLAYED ON INSTRUMENT DIGITAL WRENCH CLUSTER DIAGNOSTIC SOFTWARE 524080 U1405 Condition Exists Cruise Control Input Message Counter 524081 U1407 Condition Exists Foot On Cruise Control Input Message Counter 524082 U1406 Condition Exists Foot On Cruise Control Input Checksum 524145...

  • Page 131: Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
  • Page 132 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 133 TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer;...
  • Page 134 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 135 U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 136 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...
  • Page 137 WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
  • Page 138 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Polaris Industries Inc. is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's stringent anti-smog standards.
  • Page 139 The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As an OHRV-EVAP owner, you should also be aware that Polaris may deny you warranty coverage if your OHRV-EVAP or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 141: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 143 Drive Belt Wear/Burn....111 Drive Chain Age Restrictions ......12 Adjustment......78 AGM Battery Charging....96 Lubrication ......78 Air Filter........83 Driver’s Seat Adjustment..... 24 Air Filter / Air Box..... 101 Driving Downhill ......63 Driving Downhill Improperly ..15 Driving in Reverse .....
  • Page 144 Jumps and Stunts ...... 15 Gear Selector ......28 Gearcase / Transmission Lubricants ......109 General Warning ....... 20 Gloves ........11 Know Your Riding Area/Tread Grease / Specialized Lightly ........55 Lubricants ......109 Limited Warranty ..... 129 Hauling Cargo......59 Helmet ........
  • Page 145 Operating Without Instruction ..12 Steering Wheel ......25 Operation on Public Lands in Stopping the Engine ....57 the U.S.A........ 65 Storage ......... 101 Overloading the Vehicle ....17 Storage Area ......102 Parking Brake ...... 29, 80 Tire Pressure Warning ....22 Parking Brake Adjustment ...
  • Page 147 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9930637 Rev 01 Printed in China...

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